fuel tank removal RENAULT KANGOO 1997 KC / 1.G Engine And Peripherals Workshop Manual

FUEL SUPPLY
Fuel filter
13
LOCATION
The fuel filter is located under the vehicle, in
front of the fuel tank. Petrol
engines
99214R
SPECIAL TOOLING REQUIRED
Mot. 1265 Pliers for removing quick release
unions
REPLACEMENT
It is recommended to replace the fuel filter at
each vehicle major service.
IMPORTANT : during the opening of the fuel cir-
cuit , be sure to use a cloth to avoid possible pro-
jections of fuel due to the residual pressure.
REMOVAL
Before removing the filter take precautions to
catch fuel that will run out of the pipes (the pipes
should not be clamped as they would be dama-
ged).
Remove the clips (1).
Disconnect the pipes fitted with quick release
unions (2) using tool Mot. 1265.
96420R3
Remove bolt (3) and remove the fuel filter.
REFITTING
Observe the flow direction of the fuel (marked by
an arrow on the filter).
Reconnect the pipes by hand (tool Mot. 1265 is
not required ).
Ensure that the quick release unions are correctly
fastened .
Refit the safety clips (1).
13-6

ANTIPOLLUTION
Fuel vapour rebreathing
14
LOCATION-REMOVAL OF COMPONENTS
CANISTER BLEED SOLENOID VALVE
(1)
E7J Engine
It is mounted above the inlet manifold,
underneath the cover
D7F Engine
It is mounted at the front, on the lifting bracket.
13242R2
99939-1R3
REMOVAL OF THE FUEL VAPOUR ABSORBER (1)
This is located in the front right hand wheel arch.
REMOVAL
Disconnect the pipe connecting the canister to the
inlet manifold, from the top of the vehicle.
From the bottom, remove the wheel arch .
Disconnect the pipe at (2) connecting the
canister to the fuel tank.
Remove the three bolts at (3) mounting the
canister (1) then extract it.
13049R
14-6

Mot. 1199-01 Exhaust pipe cutting tool
Mot. 1265
Mot. 1265-01
FUEL TANK
Fuel tank
19
IMPORTANT : during all the fuel tank removal
and refitting operations, refrain from smoking
and be sure not to handle incandescent objects in
the vicinity of the working area.
DRAINING THE FUEL TANK (Petrol version)
Remove the pump-sender unit assembly steel ac-
cess cover.
Remove the clip which shows if the assembly has
been pushed in (if fitted).
Disconnect the quick release union at (1), tool
Mot. 1265.
EQUIPMENT REQUIRED
INTAIRCO pneumatic siphoning pump, for
petrol or diesel tank draining system (see EQUIPMENT
catalogue).
SPECIAL TOOLING REQUIRED
97163R2
Attach to the outlet at (A), a pipe long enough to
be placed into a container outside the vehicle .
NOTE : Alternatively, an INTAIRCO pneumatic si-
phoning pump may be used (see
EQUIPMENT ca-
talogue). Sender unit- pump nut 7
TIGHTENING TORQUES (in daN.m)
Pliers for removing quick release
fuel unions
19-17

TANK
Fuel Tank
19
REMOVAL OF THE TANK (petrol or diesel ver-
sions)
Disconnect the battery.
Place the vehicle on a two post lift.
Disconnect the electrical connector (2) and the
quick release unions, tool Mot. 1265 or Mot.
1265-01.
97163R4
Disconnect the petrol filter.
Remove the heat shields at (3) and (4) , which are
situated below the tank and beneath the hand-
brake cables.
Remove the exhaust mounting bracket (5).
Lift the vehicle.
Separate the exhaust pipe from the exhaust
down pipe.
Remove the exhaust mounting bracket from the
middle of the vehicle.
12866R
Tilt the exhaust towards the right hand side of the
vehicle.
19-19

FUEL TANK
Fuel tank
19
Before the handbrake adjuster is disengaged, di-
mension X must be noted.
Disengage the adjuster in such a way that both
the left and right hand cables can be easily relea-
sed (carefully release the plastic cable stop (6)).
Disconnect the two unions at (7) and (8) using
tool Mot. 1265.
Disconnect the pipe at (9).
Separate the tank from the filler neck (10).
Unclip the handbrake cables from under the tank
(11).Unclip the hydraulic brake pipes on the fuel tank
side.
Unclip the fuel pipes from the tank.
Position a component jack under the fuel tank.
Remove the four bolts mounting the tank.
Tilt the tank slightly forwards, then remove it.
REFITTING
Refitting is the reverse of removal.
Take care not to pinch any pipes (risk of leaks).
Fit the quick release unions by hand and ensure
they connect correctly.
Take care to ensure the heat shields are correctly
refitted.
12873R
99091R1
19-20

FUEL TANK
Sender unit
19
In petrol versions, the pump and sender unit can-
not be separated.
In diesel versions, there is no pump immersed in
the tank, and there is only a sender unit.
For the removal of the sender unit, please refer to
subsections "Tank", "Pump-sender unit".
Checking the sender unit
Check for a variation in resistance by moving the
float.
NOTE : all the above values are given merely as
an indication.
IndicationValue between terminals
A1 and B1 (in Ω)
4/4 7 maximum
3/4 54.5 ± 7
1/2 98 ± 10
1/4 155 ± 16
Low fuel level 300 ± 20
19-29

Mot. 1264 Wrench for removing
Mot. 1264-01 pump-sender unit assembly nut
Mot. 1265 Pliers for removing
Mot. 1265-01 quick release unions
FUEL TANK
Pump- sender unit
19
SPECIAL TOOLING REQUIRED
IMPORTANT :
During all operations on the fuel tank or on the
fuel supply circuit , it is vital :
- to refrain from smoking and handling incan-
descent objects in the vicinity of the working
area,
- to avoid fuel projections, due to the residual
pressure present in the pipes during removal .
REMOVAL
To remove the pump-sender unit assembly, it is
not necessary to remove the tank, as it is accessi-
ble through the inside of the vehicle. To do this :
- disconnect the battery,
- lift the rear bench seat ,
- remove the steel access cover,
- remove the electrical connection at (1),
- remove the clips at (2).
97163R5
Nut for pump - sender unit assembly 7

TIGHTENING TORQUES (in daN.m)Disconnect, using tool Mot. 1265 or Mot. 1265-
01:
- the fuel supply pipe (3) (which is marked by a
green quick release union),
- the fuel return pipe (4) (marked by a red quick
release union and by an arrow (B)).
96420R1
19-30

FUEL TANK
Pump- sender unit
19
REFITTING
Check that the seal is not deformed, and replace it
if necessary.
Position the pump-sender unit assembly
(ensuring that the arrow at (F) is placed in the
longitudinal axis of the vehicle pointing to the
rear).
Position the nut and tighten it to the torque of
3.5 daN.m.
Fit the fuel pipes (it is not necessary to use the
pliers Mot. 1265 or Mot. 1265-01).
Refit the safety clips at (2).
Reconnect the electrical connection.
Refit the steel cover.
ALLOCATION OF CONNECTOR TRACKS
TRACK ALLOCATION
A1 Earth
A2 Fuel minimum level warning light
B1 Sender unit information to instrument
panel
B2 Not used
C1 pump
C2 pump
Remove the mounting nut at (5) using tool
Mot. 1264 or 1264-01 (release the nut, remove
the tool, hand slacken the nut, then remove it).
Extract the fuel pump-sender unit assembly.
99367S
NOTE : if several hours have to pass between the
removal and refitting of the fuel pump-sender
unit assembly, refit the nut on the tank, to avoid
deforming it.
19-31